Balluff MICROPULSE+ BTL7-A501-M, MICROPULSE+ BTL7-E501-M User Manual

User’s Guide

english

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-KA_ _/FA_ _

www.balluff.com

www.balluff.com 3english

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

1

Notes to the user 5

1.1 Validity 5

1.2 Symbols and conventions 5

1.3 Scope of delivery 5

1.4 Approvals and markings 5

2

Safety 6

2.1 Intended use 6

2.2 General safety notes for the position measuring system 6

2.3 Meaning of the warnings 6

2.4 Disposal 6

3

Construction and function 7

3.1 Construction 7

3.2 Function 8

3.3 LED display 8

4

Installation and connection 9

4.1 Installation variants 9

4.2 Preparing for installation 9

4.3 Installing the transducer 10

4.3.1 Installation recommendation for hydraulic cylinders 10

4.4 Electrical connection 11

4.4.1 Connector S32/cable connection 11

4.4.2 Connector S115 11

4.4.3 Connector S140 12

4.5 Shielding and cable routing 12

5

Startup 13

5.1 Starting up the system 13

5.2 Operating notes 13

6

Configuration with the Micropulse Configuration Tool 14

6.1 Micropulse Configuration Tool 14

6.2 Connecting the USB communication box 14

6.3 Configuration options 14

7

Adjust with the calibration device (not with BTL7-...-S140) 16

7.1 Calibration device 16

7.2 Calibration procedure notes 16

7.3 Calibration procedure overview 17

7.3.1 Teach-in 17

7.3.2 Adjust 18

7.3.3 Reset 18

8

Teach-in with the calibration device 19

9

Adjust with the calibration device 20

10

Reset all values with the calibration device (reset) 23

4 english

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

11

Technical data 24

11.1 Accuracy 24

11.2 Ambient conditions 24

11.3 Supply voltage (external) 24

11.4 Output 24

11.5 Communication lines La, Lb 24

11.6 Dimensions, weights 25

12

Accessories 26

12.1 Magnets 26

12.2 Mounting nut 26

12.3 Connectors and cables 27

12.3.1 BKS-S32/S33M-00, freely configurable 27

12.3.2 BKS-S232/S233-PU-_ _, preassembled 27

12.3.3 BKS-S115/S116-PU-_ _, preassembled 28

12.3.4 BKS-S140-23-00, freely configurable 28

12.3.5 Plug-in system, 8-pin 28

12.4 USB communication box 29

13

Type code breakdown 30

14

Appendix 31

14.1 Converting units of length 31

14.2 Part labels 31

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1.1 Validity

This guide describes the construction, function and setting
options for the BTL7 Micropulse Transducer with analog
interface. It applies to types BTL7-A/E501-M_ _ _ _-A/B/
Y/Z(8)-S32/S115/S140/KA__/FA_ _ (see type code
breakdown on page30).

The guide is intended for qualified technical personnel.
Read this guide before installing and operating the
transducer.

1.2 Symbols and conventions

Individual instructions are indicated by a preceding
triangle.

Ź Instruction 1

Action sequences are numbered consecutively:

1. Instruction 1

2. Instruction 2

Note, tip

This symbol indicates general notes.

1

2

These symbols indicate the buttons on the
calibration device.

Symbols of this type indicate the LED displays.

1.3 Scope of delivery

– BTL7 transducer
– Calibration device (not with BTL7-...-S140)
– Condensed guide

The magnets are available in various models
and must be ordered separately.

1.4 Approvals and markings

UL approval

1)

File no.
E227256

1)

Not for BTL7-...-FA_ _

US Patent 5923164

The US patent was awarded in connection with this
product.

The CE Mark verifies that our products
meet the requirements of EU Directive
2004/108/EC (EMC Directive).

The transducer meets the requirements of the following
generic standards:

– EN61000-6-1 (noise immunity)
– EN61000-6-2 (noise immunity)
– EN61000-6-3 (emission)
– EN61000-6-4 (emission)

and the following product standard:
– EN61326-2-3

Emission tests:

– RF emission

EN55016-2-3 (industrial and residential areas)

Noise immunity tests:

– Static electricity (ESD)

EN 61000-4-2

Severity level 3

– Electromagnetic fields (RFI)

EN 61000-4-3

Severity level 3

– Electrical fast transients (burst)

EN 61000-4-4

Severity level 3

– Surge

EN 61000-4-5

Severity level 2

– Conducted interference induced by

high-frequency fields
EN 61000-4-6

Severity level 3

– Magnetic fields

EN 61000-4-8

Severity level 4

More detailed information on the guidelines,
approvals, and standards is included in the
declaration of conformity.

By using the GL symbol1), we confirm that the
marked products were type tested according to
the guidelines of Germanischer Lloyd.
The type approval is authenticated with a
certificate.
The verified test requirements cover the
environmental category "D" (closed
environments with increased heat and vibration
requirements).
Therefore, the marked products can be used
according to the specifications of the certificate
on ocean-going and inland vessels and on
offshore operations in systems subject to
mandatory type-testing.
Maximum length:
– BTL7-…-A/B/Y/Z-…: 300mm (500mm

when supported at the end of the rod using
slide bush BAM PC-TL-001-D10,4-4 in bore
with a diameter of max. 13mm)

1)

Not for BTL7-...-S140

1

Notes to the user

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

6 english

2.1 Intended use

The BTL7 Micropulse Transducer, together with a machine
controller (e. g. PLC), comprises a position measuring
system. It is intended to be installed into a machine or
system. Flawless function in accordance with the
specifications in the technical data is ensured only when
using original BALLUFF accessories, use of any other
components will void the warranty.

Opening the transducer or non-approved use are not
permitted and will result in the loss of warranty and liability
claims against the manufacturer.

2.2 General safety notes for the position
measuring system

Installation and startup may only be performed by

trained specialists with basic electrical knowledge.
Qualified personnel are those who can recognize
possible hazards and institute the appropriate safety
measures due to their professional training, knowledge,
and experience, as well as their understanding of the
relevant regulations pertaining to the work to be done.

The operator is responsible for ensuring that local safety
regulations are observed.
In particular, the operator must take steps to ensure that a
defect in the position measuring system will not result in
hazards to persons or equipment.
If defects and unresolvable faults occur in the transducer, it
should be taken out of service and secured against
unauthorized use.

2.3 Meaning of the warnings

Always observe the warnings in these instructions and the
measures described to avoid hazards.

The warnings used here contain various signal words and
are structured as follows:

SIGNAL WORD

Hazard type and source

Consequences if not complied with

Ź Measures to avoid hazards

The individual signal words mean:

NOTICE!

Identifies a hazard that could damage or destroy the
product.

DANGER

The general warning symbol in conjunction with the
signal word DANGER identifies a hazard which, if not
avoided, will certainly result in death or serious

injury.

2.4 Disposal

Ź Observe the national regulations for disposal.

2

Safety

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

www.balluff.com 7english

Ø D1

G

max. 7

74.5

12.8

Fig. 3-1: BTL7... transducer, construction and function

3.1 Construction

Electrical connection: The electrical connection is made

via a cable or a connector (see type code breakdown on
page30).

BTL housing: Aluminum housing containing the
processing electronics.

Mounting thread: We recommend assembling this
transducer on the fastening screw thread:

– BTL7-…-A/B: M18×1.5
– BTL7-…-Y/Z: 3/4"-16UNF
The transducers with Ø 10.2mm have an additional thread
at the end of the rod to support larger nominal lengths.

Magnet: Defines the position to be measured on the
waveguide. Magnets are available in various models and
must be ordered separately (see accessories on
page26).

Nominal length: Defines the available measuring range.
Rods with various nominal lengths from 25 mm to
7620mm are available depending on the version:

– Ø10.2mm: Nominal length from 25mm to 7620mm
– Ø8mm: Nominal length from 25mm to 1016mm

Damping zone: Area at the end of the rod that cannot be
used for measurements, but which may be passed over.

Calibration device: Additional device for calibrating the
transducer (not with BTL7-...-S140).

3

Construction and function

Calibration device

BTL7-...

-Cable

BTL7-...-S115

BTL7-...-S32

Mounting surface

Thread size:
A: M18x1.5
Y: 3/4"-16UNF

A: 30-1 mm
Y: 2"-0.04"

1)

Unusable area

2)

Not included in scope of delivery

3)

Not included in scope of delivery for BTL7-...-S140

Thread size:
B: M18x1.5
Z: 3/4"-16UNF

2)

1)

Mounting surface

Damping zone

Magnets

1)

Nominal length =

Measuring range

B: 30-1 mm
Z: 2"-0.04"

Nullpoint End point

Output signal with increasing
characteristic:

Error signal

100 %

0 %

2)

1)

BTL7-...-S140

3)

Top view of the
BTL7-...-S32

Top view of the
BTL7-...-S140

Version D1 G

...-A/B/Y/Z-... 10.2 mm Thread

M4x4/6deep

...-A8/B8/Y8/Z8-... 8 mm No thread

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

8 english

3

Construction and function (continued)

3.2 Function

The Micropulse Transducer contains the waveguide which
is protected by an outer stainless steel tube (rod). A
magnet is moved along the waveguide. This magnet is
connected to the system part whose position is to be
determined.

The magnet defines the position to be measured on the
waveguide.

An internally generated INIT pulse interacts with the
magnetic field of the magnet to generate a torsional wave
in the waveguide which propagates at ultrasonic speed.

The component of the torsional wave which arrives at the
end of the waveguide is absorbed in the damping zone to
prevent reflection. The component of the torsional wave
which arrives at the beginning of the waveguide is
converted by a coil into an electrical signal. The travel time
of the wave is used to calculate the position. Depending
on the version, this information is made available as a
voltage or current with rising or falling gradient.

The following functions can be selected for the output
values:
– Position
– Velocity (with or without leading sign)
– Differential position

Two outputs that can be independently assigned are
available. Two magnets can be used.

The entire function scope can only be
configured with the PC software "Micropulse
Configuration Tool". To do this, the USB
communication box must be connected (see
Accessories on page26). If you do not have
the PC software, the transducer can be
adjusted using the calibration device (see
page17 ff).

3.3 LED display

Fig. 3-2: Position of the

LED1 LED2

BTL7 LED displays

In normal operation, the LEDs indicate the
operating states of the transducer. LED1 is
assigned to output1, LED2 is assigned to
output2 (see page19ff).

LED1/LED2 Operating state

Green Normal function

Magnet is within the limits.

Red Error

No magnet or magnet outside the limits.

Tab. 3-1: LED displays in normal operation

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Micropulse Transducer - Rod Style

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4.1 Installation variants

Non-magnetizable material

min. Ø D2

1)

Magnet

Non-magnetizable material

1)

Min. ØD2=Minimum diameter of the bore (seeTab. 4-1)

Fig. 4-1: Installation variant in non-magnetizable material

Magnetizable material

If using magnetizable material, the transducer must be
protected against magnetic interference through suitable
measures (e.g. spacer ring made of non-magnetizable
material, a suitable distance from strong external magnetic
fields).

Spacer ring made of non-magnetizable
material

Magnet

min. Ø D2

1)

Spacer ring made of non-magnetizable
material

Magnet

1)

Min.ØD2=Minimum diameter of the bore (seeTab. 4-1)

Fig. 4-2: Installation in magnetizable material

Tube diameter Bore diameter D2

10.2mm At least 13mm

8mm At least 11mm

Tab. 4-1: Bore diameter if installed in a hydraulic cylinder

4.2 Preparing for installation

Installation note: We recommend using non-

magnetizable material to mount the transducer and
magnet.

Horizontal assembly: If installing horizontally with
nominal lengths > 500 mm, we recommend tightening the
rod at the end (only possible with Ø10.2mm) or
supporting it.

Hydraulic cylinder: If installed in a hydraulic cylinder,
ensure that the minimum value for the bore diameter of the
support piston is complied with (seeTab. 4-1).

Mounting hole: The transducer comes with an M18×1.5
(ISO) or 3/4"-16UNF (SAE) mounting thread. Depending on
the version, a mounting hole must be made before
assembly.

Fig. 4-3: Mounting hole M18x1.5 per ISO6149 O-ring15.4x2.1

Fig. 4-4:

Mounting hole 3/4"-16UNF per SAE J475 O-ring15.3x2.4

Magnet: Various magnets are available for the BTL7
transducer (see Accessories on page26).

4

Installation and connection

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

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4.3 Installing the transducer

NOTICE!

Interference in function

Improper installation can compromise the function of the
transducer and result in increased wear.

Ź The mounting surface of the transducer must make

full contact with the supporting surface.

Ź The bore must be perfectly sealed (O-ring/flat seal).

Ź Make a mounting hole with thread (possibly with

countersink for the O-ring) acc. to Fig. 4-3 or Fig. 4-4.

Ź Screw the transducer with fastening screw thread into

the mounting hole (max. torque100Nm).
Ź Install the magnet (accessories).
Ź For nominal lengths>500mm: Tighten the rod at the

end (only possible with Ø10.2mm) or support it.

Suitable nuts for the mounting thread are
available as accessories (see page26).

4.3.1 Installation recommendation for hydraulic
cylinders

If you seal the hole with a flat seal, the max. operating
pressure will be reduced in accordance with the larger
pressurized surface.
If installing horizontally in a hydraulic cylinder (nominal
lengths>500mm), we recommend affixing a slide element
to protect the rod end from wear.

Dimensioning of the detailed solutions is the
responsibility of the cylinder manufacturer.

The slide element material must be suitable for the
appropriate load case, medium used, and application
temperatures. E.g. Torlon, Teflon or bronze are all possible
materials.

Fig. 4-5:

Slide element

Magnet

Example 1, transducer installed with slide element

The slide element can be screwed on or bonded.

Ź Secure the screws so they cannot be loosened or lost.
Ź Select a suitable adhesive.

Slide element

BTL rod

Piston rod

Slide surface

Flow gap

Fig. 4-6: Detailed view and top view of slide element

There must be a gap between the slide element and piston
bore that is sufficiently large for the hydraulic oil to flow
through.

Options for fixing the magnet:
– Screws

– Threaded ring
– Press fitting
– Notches (center punching)

If installed in a hydraulic cylinder, the magnet
should not make contact with the rod.

The hole in the spacer ring must ensure optimum guidance
of the rod by the slide element.

Fig. 4-7:

Spacer ring

Magnet

Fixing of magnet

Fixing of magnet

An example of how to install the transducer with a
supporting rod is shown in Fig. 4-8 on page11.

4

Installation and connection (continued)

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

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Fig. 4-8:

Magnet
(e.g. BTL-P-1028-15R)

Supporting rod made of non-magnetizable material

Example2, transducer installed with supporting rod

4.4 Electrical connection

Depending on the model, the electrical connection is made
using a cable or a connector.
The connection or pin assignments for the respective
version can be found in Tab. 4-2 to Tab. 4-4.

Note the information on shielding and cable
routing on page12.

4

Installation and connection (continued)

4.4.1 Connector S32/cable connection

S32

Pin

Cable color BTL7-... interface

Fig. 4-9: Pin assignment of S32

connector (view of connector
pins of transducer)

-A501 -E501

1 YE yellow Not used

1)

4 to 20mA2) (output1)

2 GY gray 0V

3 PK pink 10 to 0V

2)

(output2) 20 to 4mA2) (output2)

4 RD red La (communication line)

5 GN green 0 to 10V

2)

(output1) Not used

1)

6 BU blue GND

3)

7 BN brown 10 to 30V

8 WH white Lb (communication line)

Tab. 4-2: Connection assignment BTL7...S32/cable

4.4.2 Connector S115

S115

Pin

BTL7-... interface

Fig. 4-10: Pin assignment of S115

connector (view of connector
pins of transducer)

-A501 -E501

1 0V (pin 3)

2 0V (pin 5)

3 10 to 0V

2)

(output2) 20 to 4mA2) (output2)

4 La (communication line)

5 0 to 10V

2)

(output1) 4 to 20mA2) (output1)

6 GND

3)

7 10 to 30V

8 Lb (communication line)

Tab. 4-3: Connection assignment BTL7...S115

1)

Unassigned leads can be connected to the GND on the controller side but not to the shield.

2)

Factory setting, can be freely configured with the PC software.

3)

Reference potential for supply voltage and EMC-GND.

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

12 english

4.4.3 Connector S140

S140

Pin

BTL7-... interface

A
B

C

J

K

G

H

E

D

F

Fig. 4-11: Pin assignment of S140 (view of

connector pins of transducer),
10-pin circular plug

-A501 -E501

A 0 V

B Not used

1)

4 to 20mA2) (output1)

C 10 to 0V

2)

(output2) 20 to 4mA2) (output2)

D 10 to 30V

E Not used

1)

F GND

3)

G La (communication line)

H Lb (communication line)

J 0 to 10V

2)

(output1) Not used

1)

K Not used

1)

Tab. 4-4: Connection assignment BTL7...-S140

1)

Unassigned leads can be connected to the GND on the controller side but

not to the shield.

2)

Factory setting, can be freely configured with the PC software.

3)

Reference potential for supply voltage and EMC-GND.

4.5 Shielding and cable routing

Defined ground!

The transducer and the control cabinet must be
at the same ground potential.

Shielding

To ensure electromagnetic compatibility (EMC), observe
the following:

– Connect transducer and controller using a shielded

cable.
Shield: Braided copper shield with minimum 85%
coverage.

– Connector version: Shield is internally connected to

connector housing.

– Cable version: On the transducer side, the cable

shielding is connected to the housing. Ground the
cable shielding on the controller side (connect with the
protective earth conductor).

Magnetic fields

The position measuring system is a magnetostrictive
system. It is important to maintain adequate distance
between the transducer cylinder and strong, external
magnetic fields.

Cable routing

Do not route the cable between the transducer, controller,
and power supply near high voltage cables (inductive stray
noise is possible).
The cable must be routed tension-free.

4

Installation and connection (continued)

Bending radius for fixed cable

The bending radius for a fixed cable must be at least five
times the cable diameter.

Cable length

BTL7-A Max. 30 m

1)

BTL7-E Max. 100 m

1)

Tab. 4-5: Cable lengths BTL7

1)

Prerequisite: Construction, shielding and routing preclude the effect of any

external noise fields.

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5

Startup

5.1 Starting up the system

DANGER

Uncontrolled system movement

When starting up, if the position measuring system is
part of a closed loop system whose parameters have not
yet been set, the system may perform uncontrolled
movements. This could result in personal injury and
equipment damage.

Ź Persons must keep away from the system's

hazardous zones.

Ź Startup must be performed only by trained technical

personnel.

Ź Observe the safety instructions of the equipment or

system manufacturer.

1. Check connections for tightness and correct polarity.

Replace damaged connections.

2. Turn on the system.

3. Check measured values and adjustable parameters

and readjust the transducer, if necessary.

Check for the correct values at the null point
and end point, especially after replacing the
transducer or after repair by the manufacturer.

5.2 Operating notes

– Check the function of the transducer and all associated

components on a regular basis.

– Take the position measuring system out of operation

whenever there is a malfunction.

– Secure the system against unauthorized use.

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

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6

Configuration with the Micropulse Configuration Tool

6.1 Micropulse Configuration Tool

NOTICE!

Interference in function

Configuration with the Micr

opulse Configuration Tool

while the system is running may result in malfunctions.

Ź Stop the system before configuration.

The BTL7-A/E… USB-Configurable transducer can be
configured quickly and simply on a PC using the
Micropulse Configuration Tool PC software.
The most important features include:

–

Online display of the current position of the magnet

–

Graphical support for setting the functions and curves

–

Display of information on the connected transducer

–

Selectable number formats and units for display

–

Resetting to factory settings is possible

–

Demo mode without having transducer connected

The PC software and associated manual can
be found in the Internet under www.balluff.com/
downloads-btl7.

6.2 Connecting the USB communication box

With BTL7-A/E... transducers with connectors, the
communication box must be looped in between the
transducer and controller. The communication box is
connected to the PC via a USB cable.

Fig. 6-1:

Connecting the communication box with a connector

With a BTL7-A/E…-Cable transducer, the communication
lines La, Lb and GND must be connected to the USB
communication box.

Fig. 6-2:

Connecting the communication box with a cable connec­tion

When reading or writing data via the
Configuration Tool, both LEDs flash green.

6.3 Configuration options

Prerequisites

–

USB communication box connected to the transdu

cer

and PC.

–

Software correctly installed.

–

Transducer connected to the power supply.

–

Magnet on transducer.

Magnets and outputs

– One or two magnets can be selected (factory setting:

one magnet)

–

Two outputs can be assigned independently

Output functions

–

Position: position in the measuring range.

–

Velocity: velocity of the magnet. The sign indicates th

e

dir

ection of movement. Movement from the null p

oint
to the end point is output with a positive sign.
Movement from the end point to the null point is output
with a negative sign. Max. detectable velocity range of
10to+10m/s.

– Velocity (no sign): velocity of the magnet. The

dir

ection of movement cannot be r

ead. Max.

detectable velocity range of 0to10m/s.

–

Differential position:

Distance between two magnets.
Selection is only possible if two magnets have been
selected.

USB cable

6-pin8-pin

Connection cable approx. 0.3m with
connector (socket)

Connection cable
approx.0.3m with
connector (plug)

Controller

8-pin

USB cable

Controller

Connection cable
approx. 0.6m with
luster terminal

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6

Configuration with the Micropulse Configuration Tool (continued)

Freely configurable curve

– Null and end points can be read (teach-in) or specified

with the mouse.

– For position, the distance between the null point and

end point must be at least 4mm (0.15inch) and
100mm/s (4inch/s) for velocity.

– The curve can be inverted or copied from the other

output.
– The limits can be adjusted to the measuring range.
– The error value can be set in accordance with the

limits.

Boundary conditions for two magnets

– Two magnets can only be selected if the nominal length

is ≥90 mm.
– The distance between two magnets must be ≥65 mm.

Locking the calibration device

The function to manually adjust the transducer with the
calibration device can be locked, making configuration only
possible with the PC software.

DANGER

Uncontrolled system movement

When starting up, if the position measuring system is
part of a closed loop system whose parameters have not
yet been set, the system may perform uncontrolled
movements. This could result in personal injury and
equipment damage.

Ź The system must be taken out of operation befor

e

configuration.

Ź Transducers may only be connected to the

communication box for configuration.

Ź The communication box must be removed after

configuration.

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

16 english

7

Adjust with the calibration device (not with BTL7-...-S140)

7.1 Calibration device

The calibration device is an additional device for calibrating

the transducer if configuration with a PC and software is

not possible.

Prerequisite

– Button function has not been locked by the PC

software (button lock).
– Calibration device is in place
– The transducer is connected to the system controller.
– Voltage or current values from the transducer can be

read (using a multimeter or the system controller).

If the button function is locked, this lock must
be removed using the PC software.

Settings

The transducer has the following factory settings that can
be adjusted with the calibration device:

– One magnet,
– "position" function at both outputs, output1 with a

rising curve and output2 with a falling curve,
– identical measuring range for both outputs.

During adjustment, the same start points and end points
are set for both outputs. No other function can be selected
and no further transducer may be used.
If the button function is locked, the lock can only be
removed if these conditions have been fulfilled.

7.2 Calibration procedure notes

Ź Before calibrating: Place the calibration device on the

connection side of the transducer.

Ź When finished with calibration: Remove the calibration

device to prevent changes.

Ź Keep the calibration device for later use.

Automatic deactivation!

If the buttons on the calibration device are not
pressed for approx.10min, programming
mode is automatically ended.

Values for null and end point

– Any desired position of the magnet can be used as the

null or end point. However, the null and end points may
not be reversed.

– The absolute null and end points must lie within the

minimum or maximum limits of what can be output.

– The distance between the null point and end point

must be at least 4mm.

The last set values are always saved, regardless
of whether the setting was ended using the
buttons or automatically after 10min have
expired.

Fig. 7-1: Calibration device in place

Button 1 (blue) Button 2 (gray)

Output gradient Linear

transducer

Unit Min. value Nullvalue End value Max. value Error

value

Rising (output1) BTL7-A… V 0.5 0 +10.0 +10.5 +10.5

BTL7-E… mA 3.6 4.0 20.0 20.4 3.6

Falling (output2) BTL7-A… V +10.5 +10.0 0 0.5 0.5

BTL7-E… mA 20.4 20.0 4.0 3.6 3.6

Tab. 7-1: Factory settings value table

Null point

End point

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Micropulse Transducer - Rod Style

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New null point

Before

After

Falling

Rising

New end point

Before

After

New measuring length 100%

7

Adjust with the calibration device (continued)

7.3 Calibration procedure overview

7.3.1 Teach-in

The detailed procedure for teach-in is described
on page20.

The factory set null point and end point is replaced by a
new null point and end point. The null point and end point
can be set separately, the output gradient changes.

Steps

Ź Move magnet to the new null position.
Ź Read new null point by pressing the buttons.

 The current end point remains the same.

Fig. 7-2: Reading new null point

Ź Move magnet to the new end position.
Ź Read new end point by pressing the buttons.

 The current null point remains the same.

Fig. 7-3: Reading new end point

Ź The curves can be inverted by actuating the button.

 During inverting, the curves of both outputs are

inverted. For example, a rising curve for output 1 is
changed to a falling curve and a falling curve from
output 2 is changed to a rising curve.

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

18 english

7

Adjust with the calibration device (continued)

7.3.2 Adjust

The detailed procedure for adjustment is
described on page21 ff.

The factory set null point and end point is replaced by a
new start point and end point and the associated output
values can be adjusted. The start and end values can be
adjusted as you like up to the limits. The change to the
output value can be read out at output 1 (in the delivery
state).

As standard, the values are adjusted at output1
and the values at output2 are inverted
accordingly.
From serial number 100503000xxxxx xx, it is
possible to optionally switch adjustment from
output1 to output2 (see page 22).

Steps

Ź Move magnet to the new start position.
Ź Read new start point by pressing the buttons.
Ź Set the new start value by pressing the buttons.

Fig. 7-4: Adjust a new start value

Ź Move magnet to the new end position.
Ź Read new end point by pressing the buttons.
Ź Set the new end value by pressing the buttons.

Fig. 7-5: Adjust a new end value

7.3.3 Reset

The detailed procedure for the reset is
described on page23.

Restoring the transducer to its factory settings.

New
start value

Start point

Before

After

New end value

Before

After

End point

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

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8

Teach-in with the calibration device

NOTICE!

Interference in function

Teach-in while the system is running may result in
malfunctions.

Ź Stop the system before performing teach-in.

LED display Displayed values (example)

LED1 LED2 At 0 to 10 V At 4 to 20 mA

Initial situation:

– Transducer with magnet within measuring range

5.39 V 9.15 mA

Activate teach-in

Ź Press

n

for at least 4s.

> 4 s

1

5.39 V 9.15 mA

Set null point

Ź Bring magnet to the new null point.

1.04 V 4.82 mA

Ź Press

n

for at least 2s.

> 2s

1

 The new null point is set once the button is

released.

0.00 V 4.00 mA

Set end point

Ź Bring magnet to the new end point.

9.89 V 19.13 mA

Ź Press

d

for at least 2s.

> 2s

2

 The new end point is set once the button is

released.

10.00 V 20.00 mA

Invert curves

Ź Simultaneously press

n

and d for at least 4s, until

both LEDs are illuminated in red.

1

2

> 4s

 The curves of both outputs are inverted once the

buttons are released.

End teach-in

Ź Briefly press

n

and d simultaneously (<1 s).

< 1s

1

2

 The current position value is displayed once the

buttons are released.

Any of the individual steps for settings can be
selected. The teach-in process can be ended at
any time.

LED legend: LED not on

LED green

LED 1 and LED 2 flashing green-green in
alternation

LED red

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

20 english

9

Adjust with the calibration device

NOTICE!

Interference in function

Adjustment while the system is running may result in
malfunctions.

Ź Stop the system before performing adjustment.

LED display Displayed values (example)

LED1 LED2 At 0 to 10 V At 4 to 20 mA

Initial situation:

– Transducer with magnet within measuring range

5.39 V 9.15 mA

Activate adjusting

Ź Press

d

for at least 4s.

> 4 s

2

5.39 V 9.15 mA

Set start point

Ź Bring magnet to the new start point.

1.04 V 4.82 mA

Ź Press

n

for at least 2s.

> 2s

1

 The new start point is set with the last valid start

value.

0.00 V 4.00 mA

Adjust start value

Ź The start value can be changed using

n

and

d

1)

.

The gradient of the curve changes (see page18).

0.00 V 4.00 mA

2.00 V 7.20 mA

Ź End calibration procedure: Briefly press

n

and d

simultaneously (<1 s).

 Set position value is saved.

< 1s

1

2

2.00 V 7.20 mA

For setting the end point, adjusting the end value,
and exiting adjustment, see page 21.

Any of the individual steps for settings can be
selected. The adjustment process can be
ended at any time.

1

2

1

2

1) Briefly press button: Current value is increased or
decreased by approx. 1 mV or 1PA.
If a button is held down longer than 1s, the step
interval is increased.

LED legend:

LED not on

LED green LED 1 and LED 2 flashing green-red in alternation

LED 1 and LED 2 flashing red-red in alternation

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
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1

2

1

2

9

Adjust with the calibration device (continued)

LED display Displayed values (example)

LED1 LED2 At 0 to 10 V At 4 to 20 mA

Set end point

Ź Bring magnet to the new end point.

9.89 V 19.13 mA

Ź Press

d

for at least 2s.

> 2s

2

 The new end point is set with the last valid end

value.

10.00 V 20.00 mA

Adjust end value

Ź The end value can be changed using

n

and

d

1)

.

The gradient of the curve changes (see page18).

10.00 V 20.00 mA

8.00 V 16.80 mA

Ź End calibration procedure: Briefly press

n

and d

simultaneously (<1 s).

 Set position value is saved.

< 1s

1

2

8.00 V 16.80 mA

End adjustment

Ź Briefly press

n

and d simultaneously (< 1 s).

< 1s

1

2

 The current position value is displayed once the

buttons are released.

Any of the individual steps for settings can be
selected. The adjustment process can be
ended at any time.

1) Briefly press button: Current value is increased or
decreased by approx. 1 mV or 1PA.
If a button is held down longer than 1s, the step
interval is increased.

LED legend:

LED not on

LED green LED 1 and LED 2 flashing red-green in alternation

LED 1 and LED 2 flashing red-red in alternation

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

22 english

9

Adjust with the calibration device (continued)

Switch the output to be adjusted (optional)

As standard, the values are adjusted at output1
and the values at output2 are inverted
accordingly.
From serial number 100503000xxxxx xx, it is
possible to optionally switch adjustment from
output1 to output2.

LED display Displayed values (example)

LED1 LED2 At 0 to 10 V At 4 to 20 mA

Initial situation:

– Transducer with magnet within measuring range

5.39 V 9.15 mA

Activate adjusting

Ź Press

d

for at least 4s.

> 4 s

2

5.39 V 9.15 mA

Switch the output to be adjusted

Ź Press

n

and d for at least 4s, until one LED flashes

green.

1

2

For output 2 or

for output 1 (changes with
each switch)

 Both LEDs will flash again once the buttons are

released.

Ź Continue with Set start point (see page20).

LED legend: LED not on

LED green

LED flashing green LED 1 and LED 2 flashing red-red in alternation

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Micropulse Transducer - Rod Style

www.balluff.com 23english

10

Reset all values with the calibration device (reset)

NOTICE!

Interference in function

Resetting all values while the system is running may
result in malfunctions.

Ź Stop the system before performing the reset.

The reset function can be used to restore all the settings to
the factory settings. For a reset the magnet may also be
located outside the measuring range.

LED display

LED1 LED2

Activate reset

Ź Simultaneously press

n

and d for at least 4s.

> 4 s

1

2

Ź Release buttons.

 Reset is activated.

Reset

Ź Press

n

and d for at least 4s.

> 4s

1

2

Ź Release buttons.

 All values are reset.
 Current position value is displayed.
 Reset is deactivated.

Abort reset

Resetting can be aborted without any changes
being saved after the Activate reset step.

Ź Briefly press

n

and d simultaneously (<1s).

< 1s

1

2

Ź Release buttons.

 Current position value is displayed.

LED legend: LED not on

LED green

LED flashing green-red LED 1 and LED 2 flashing green-red simultaneously

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

24 english

11.1 Accuracy

The specifications are typical values for the BTL7-A/E... at
24VDC and room temperature, with a nominal length of
500mm in conjunction with the BTL-P-1013-4R,
BTL-P-1013-4S, BTL-P-1012-4R or BTL-P-1014-2R
magnet.
The BTL is fully operational immediately, with full accuracy
after warm-up.

For special versions, other technical data may
apply.
Special versions are indicated by the suffix -SA
on the part label.

Repeat accuracy
Voltage, typical
Current, typical

±10µm
±5µm

Sampling rate
W

ith one magnet:
Dependent on the nominal length
At nominal length 500mm
With two magnets:
Dependent on the nominal length
At nominal length 500mm

250 µs

1)

to 5.7 ms

500 µs

375 µs

1)

to 8.55 ms

750 µs

Non-linearity at
Nominal length d500mm
Nominal length >500 to
d5500mm
Nominal length >5500mm

±50µm

±0.01% FS
±0.02% FS

Temperature coefficient

2)

d30ppm/K

Max. detectable velocity 10m/s

11.2 Ambient conditions

Operating temperature 40°C to +85°C

Operating temperature for UL
(only BTL7-...-KA...)

Max.+80°C

Storage temperature 40°C to +100°C

Relative humidity <90%, non-condensing

Rod pressure rating (when
installed in hydraulic cylinders)

For Ø8mm

<250bar

For Ø10.2mm

<600bar

Shock rating
per EN60068-2-27

4)

150g/6ms

Continuous shock
per EN60068-2-29

4)

150g/2ms

Vibration
per EN 60068-2-6

4)

(note

resonant frequency of therod)

20g, 10 to 2000Hz

Degree of protection per
IEC60529

Connector (when attached) IP 67
Cable IP 68

4)

11.3 Supply voltage (external)

Voltage, stabilized

5)

10 to 30VDC

Ripple d0.5V

ss

Current draw (at24VDC)
BTL7-A501-...
BTL7-E501-...

d150mA
d180mA

Inrush current d500mA/10ms

Reverse polarity protection

6)

Up to 36V

Overvoltage protection Up to 36V

Dielectric strength
(GND to housing)

500VAC

11.4 Output

BTL7-A501
Output voltage
Max. configuration

7)

Factory setting
Load current

10 to 10V / 10 to 10V
0 to 10V / 10 to 0V
d5mA

BTL7-E501
Output current
Max. configuration

7)

Factory setting
Load resistance

0 to 20mA / 20 to 0mA
4 to 20mA / 20 to 4mA
d500ohms

Short circuit resistance Signal cable to 36V

Signal cable to GND

11.5 Communication lines La, Lb

Short circuit resistance Signal cable to GND

1)

Only position output. For velocity output, next-higher measured value rate

(500µs or 750µs).

2)

Nominal length = 500 mm, magnet in the middle of the measuring range

3)

For

: Use in enclosed spaces and up to a height of 2000 m above sea

level.

4)

Individual specifications as per Balluff factory standard

5)

For

: The transducer must be externally connected via a limitedenergy

circuit as defined in UL 61010-1, a low-power source as defined in

UL60950-1, or a class 2 power supply as defined in UL 1310 or

UL1585.

6)

A prerequisite is that no current can flow between GND and 0V in the

event of polarity reversal.

7)

Only with PC software (Configuration Tool)

11

Technical data

3)

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

www.balluff.com 25english

11

Technical data (continued)

11.6 Dimensions, weights

Diameter of rod 8mm or 10.2mm

Nominal length

For Ø8mm 25 to 1016mm
For Ø10.2mm 25 to 7620mm

Weight (depends on
length)

Approx. 2kg/m

Housing material Anodized aluminum

Rod material Stainless steel 1.4571

Rod wall thickness

For Ø8mm 0.9mm
For Ø10.2mm 2mm

Young's modulus Approx. 200kN/mm

2

Housing mounting via
threads

M18×1.5 or 3/4"-16UNF

Tightening torque Max.100Nm

BTL7-...-KA__

Cable material PUR

cULus20549
80°C, 300V,
internal wiring

Cable temperature –40°C to +90°C

Cable diameter Max. 7mm

Permissible bending
radius

Fixed routing ≥35mm
Movable ≥105mm

BTL7-...-FA__

Cable material PTFE

No UL approval available

Cable temperature –55°C to +200°C

Cable diameter Max. 7mm

Permissible bending
radius

Fixed routing ≥35mm
Movable No permissible bending

radius

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

26 english

Accessories are not included in the scope of delivery and
must be ordered separately.

12.1 Magnets

Fig. 12-1:

BTL-P-1013-4R

BTL-P-1013-4S

BTL-P-1012-4R

BTL-P-1014-2R

Magnet installation dimensions

BTL-P-1013-4R, BTL-P-1013-4S, BTL-P-1012-4R,
BTL-P-1014-2R:

Weight: Approx. 10g

Housing: Anodized aluminum

Included in the scope of delivery for the
BTL-P-1013-4R, BTL-P-1013-4S, BTL-P-1012-4R:

Spacer: 8mm, material: polyoxymethylene

(POM)

BTL5-P-4500-1 magnet (solenoid):

Weight: Approx. 90g

Housing: Plastic

Operating
temperature:

40°C to 60°C

BTL-P-1028-15R (special accessories for
applications with a supporting rod):

Weight: Approx. 68g

Housing: Anodized aluminum

Fig. 12-2:

Ø 4.3

120°

Ø 28

Ø 54

Ø 65

8

Special accessories BTL-P-1028-15R

12.2 Mounting nut

– M18×1.5 mounting nut:

BTL-A-FK01-E-M18×1.5

– Mounting nut 3/4”-16UNF:

BTL-A-FK01-E-3/4”-16UNF

12

Accessories

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

www.balluff.com 27english

12.3 Connectors and cables

12.3.1 BKS-S32/S33M-00, freely configurable

BKS-S32M-00

Straight connector, freely configurable
M16 per IEC130-9, 8-pin

Fig. 12-3:

~ 62

Connector BKS-S32M-00

BKS-S33M-00

Angled connector, freely configurable
M16 per IEC130-9, 8-pin

Fig. 12-4:

Ø 18

31

37.2

Ø 20

Ø 6 - Ø 8

~ 54

Connector BKS-S33M-00

12.3.2 BKS-S232/S233-PU-_ _, preassembled

BKS-S232-PU-_ _

Straight connector, molded, preassembled
M16, 8-pin
Various cable lengths can be ordered, e.g.
BKS-S232-PU-05: Cable length 5m

Fig. 12-5:

Ø 20

66

Connector BKS-S232-PU-_ _

BKS-S233-PU-_ _

Angled connector, molded, preassembled
M16, 8-pin
Various cable lengths can be ordered, e.g.
BKS-S233-PU-05: Cable length 5m

Fig. 12-6:

Ø 20

46

48.5

Connector BKS-S233-PU-_ _

The outlet direction and the pin assignment for
the BKS-S233-PU-_ _ is the same as that for
the BKS S116-PU-_ _ (sea Fig. 12-9 or
Tab. 12-1).

12

Accessories (continued)

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

28 english

12

Accessories (continued)

12.3.3 BKS-S115/S116-PU-_ _, preassembled

BKS-S115-PU-_ _

Straight connector, molded-on cable, preassembled
M12, 8-pin
Various cable lengths can be ordered, e.g.
BKS-S115-PU-05: Cable length 5m

Fig. 12-7:

43

Ø 13.5

M12x1

Connector BKS-S115-PU-_ _

BKS-S116-PU-_ _

Angled connector, molded-on cable, preassembled
M12, 8-pin
Various cable lengths can be ordered, e.g.
BKS-S116-PU-05: Cable length 5m

Fig. 12-8:

28

M12x1

Connector BKS-S116-PU_ _

Fig. 12-9:

Connector BKS-S116-PU_ _, outlet

Pin Color

1 YE yellow

2 GY gray

3 PK pink

4 RD red

5 GN green

6 BU blue

7 BN brown

8 WH white

Tab. 12-1: BKS-S115/S116-PU_ _ pin assignment

12.3.4 BKS-S140-23-00, freely configurable

BKS-S140-23-00

Straight connector, freely configurable
10-pin

Fig. 12-10:

50

Ø

26

Connector BKS-S140-23-00

12.3.5 Plug-in system, 8-pin

The transducer is available with an 8-pin pigtail plug-in
system. The plug-in system has two parts:

– The M12 contact insert is preassembled to the

transducer’s cable

– The square flange for assembly using the contact insert

is included in the scope of delivery.

Fig. 12-11:

Square flange

M12 contact insert

Plug-in system based on the example installing the
transducer in a hydraulic cylinder

Series ZA10

Square flange material: Nickel-plated brass
BTL7-…-KA00,2-ZA10, PUR cable 0,2 m
BTL7-…-KA00,3-ZA10, PUR cable 0,3 m

Series ZA15

Square flange material: Stainless steel 1.4404
BTL7-…-KA00,2-ZA15, PUR cable 0,2 m
BTL7-…-KA00,3-ZA15, PUR cable 0,3 m

Fig. 12-12:

20

5

3

M12x1

14

20

Ø 3.2

Square flange

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

www.balluff.com 29english

12

Accessories (continued)

12.4 USB communication box

BTL7-A-CB01-USB-S32

For BTL7-A/E501-... with S32 connector.
Scope of delivery: USB communication box, USB cable,
2adapter cables each approx. 0.3m, condensed guide.

BTL7-A-CB01-USB-S115

For BTL7-A/E501-... with S115 connector.
Scope of delivery: USB communication box, USB cable,
2adapter cables each approx. 0.3m, condensed guide.

BTL7-A-CB01-USB-S140

For BTL7-A/E501-... with S140 connector.
Scope of delivery: USB communication box, USB cable,
2adapter cables each approx. 0.3m, condensed guide.

BTL7-A-CB01-USB-KA

For BTL7-A/E501-... with cable connection
Scope of delivery: USB communication box, USB cable,
1adapter cable approx. 0.6m, condensed guide.

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

30 english

13

Type code breakdown

BTL7 - A 5 0 1 - M0500 - B - S32

Micropulse transducer

Interface:

A = Analog interface, voltage output 0 to 10 V (Factory setting)

E = Analog interface, current output 4 to 20 mA (Factory setting)

Supply voltage:

5 = 10 to 30VDC

Output gradient:

01 = 2 outputs, configurable

Nominal stroke (4-digit):

M0500 = Metric specification in mm, nominal length 500mm

(M0025 to M1016: A8, B8, Y8, Z8)

(M0025 to M7620: A, B, Y, Z)

Rod version, fastening:

A = Metric mounting thread M18x1.5, rod diameter 10.2mm

B = Metric mounting thread M18x1.5, O-ring, rod diameter 10.2mm

Y = 3/4"-16UNF thread, rod diameter 10.2mm

Z = 3/4"-16UNF thread, O-ring, rod diameter 10.2mm

A8 = Metric mounting thread M18x1.5, rod diameter 8mm

B8 = Metric mounting thread M18x1.5, O-ring, rod diameter 8mm

Y8 = 3/4"-16UNF thread, rod diameter 8mm

Z8 = 3/4"-16UNF thread, O-ring, rod diameter 8mm

Electrical connection:

S32 = 8-pin, M16 plug per IEC130-9

S115 = 8-pin, M12 plug

S140 = 10-pin, plug

KA05 = Cable, 5m (PUR)

FA05 = Cable, 5m (PTFE)

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style

www.balluff.com 31english

14.1 Converting units of length

1mm=0.0393700787inch

mm inches

1 0.03937008

2 0.07874016

3 0.11811024

4 0.15748031

5 0.19685039

6 0.23622047

7 0.27559055

8 0.31496063

9 0.35433071

10 0.393700787

Tab. 14-1: Conversion table mm to inches

1inch=25.4mm

inches mm

1 25.4

2 50.8

3 76.2

4 101.6

5 127

6 152.4

7 177.8

8 203.2

9 228.6

10 254

Tab. 14-2: Conversion table inches to mm

14.2 Part labels

2)

3)

3)

1)

1)

Ordering code

2)

Type

3)

Serial number

Fig. 14-1: BTL7 part label

14

Appendix

BTL7-A/E501-M_ _ _ _-A/B/Y/Z(8)-S32/S115/S140/KA_ _/FA_ _
Micropulse Transducer - Rod Style